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COURSE TITLE:
PRODUCTION MANAGEMENT I
1
ENT 417
PRODUCTION
MANAGEMENT I
COURSE GUIDE
2
TABLE OF CONTENT
1.0. Introduction - - - - 3
2.0. Course Content - - - - 3
3.0. Course Aims - - - - 3
4.0. Objectives - - - - 3
5.0. Course Materials - - - - 3
6.0. Study Units - - - - 3-4
7.0. The Modules - - - - 4
8.0. Assignment - - - - 4
9.0. Assessment - - - - 4
10.0 Summary - - - - 4
1.0. INTRODUCTION
ENT 417 – Production Management I - is a semester course work of three credit
hours. It will be available to all students taking the B.Sc. Programme in the School of
Business and Human Resources Management.
3
The Course Guide tells you what ENT 417 is all about, the material you will be using
and how to make use of them.
4.0. OBJECTIVES
After going through this course, you should be able to:
(i) Explain the concept and scope of production
(ii) Identify the key principles, practices and techniques of production
(iii) State the constraints of production policy.
4
Contained in each unit are: Introduction, Objectives, Main Content, Exercise,
Conclusion, Summary and References.
8.0. ASSIGNMENT
Each unit will contain at least one assignment which you are expected to do carefully.
9.0. ASSESSMENT
10.0. SUMMARY
ENT 417 – Production Management I – will expose you to the principles and
practices of production management. The course will equip you to face the
challenges of production in the industries or related organizations.
TABLE OF CONTENT
5
1.0. Introduction - - - - 6
2.0. Objectives - - - - 6
3.0. The Nature and Scope of Production - - - - 6
3.1. The Meaning of Production - - - - 6
3.2. Aspects of Production - - - - 6-7
3.2.1. Market Consideration - - - - 7
3.2.2. Production to Order - - - - 7
3.2.3. Design and Technical Problems - - - - 7
3.2.4. Availability of Resources - - - - 7
3.2.5. Purchasing and Marketing - - - - 7
3.2.6. Assimilation into Existing Production - - - - 8
3.3. Production Policy - - - - 8
3.4 Self Assessment Question - - - - 9
3.5 Self Assessment Answer - - - - 9
4.0 Conclusion - - - - 10
5.0 Summary - - - - 10
6.0 Tutor Marked Assignment - - - - 11
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 11
7.0 References - - - - 12
1.0. INTRODUCTION
This Unit will take a look at the nature of production vis-à-vis the meaning, aspects
and policy of production.
2.0. OBJECTIVES
At the end of this Unit, students should be able to:
6
(i) State the meaning of production.
(ii) Identify the various aspects of production.
(iii) State the constraints of production policy.
According to Pitfield (1984), production in its strictest term, means the making of
things by the conversion of materials and/or assembly of component into marketable
objects.
In a wider context, Needle (1999) sees the production function operating in every
department, store, restaurant, Bank, Local Government, School and hospital. The
implication of this is that the production function operates in both the manufacturing
and the non-manufacturing sector of the economy. When production is viewed in this
wider perspective, it is referred to as operations. For instance, the school system at
various levels produces graduates such as School Certificate holders, Diploma
graduates, Polytechnic graduates and University graduates. The church produces
converts who are then referred to as being ‘born-again’ with different levels of
spirituality.
7
The Market is a critical factor to be considered before goods and services are
produced.
With the exception of commissioned products, the quantity and quality of goods to be
produces must be estimated based on the knowledge of the supply-gap that exist in the
market. Answers must be sought to the questions:
• Is there a supply gap?
• What is the degree of sales of existing products?
• Is there need for a new product?
• What will be the potential sales of a new product?
• What will the quantity and the quality of the product to be produced.
• At what price?
Answers to these questions can be obtained through market research or market
survey.
8
The range of product must be established, and the degree of specialization
established.
(e) Finance
Money is required to finance a business until the point of profitability is
reached.
9
• Consideration of the market
• Production to order
• Design and technical problem
• Availability of resources
• Purchasing and marketing
• Assimilation into existing production
4.0. CONCLUSION
Production in its strictest term is limited to manufacturing but in broader perspectives,
production exists in all organizations.
5.0. SUMMARY
10
Production is a central function in all organizations. It has a viable relationship with
its environment. Key aspects of production include:
• Market consideration
• Design and technical problems
• Availability of resources etc.
11
• Limitation of range
• Availability of resources
• Level of production
• Cost and price
• Finance
• Managerial expertise
MARKING SCHEME
2 marks for each constraint identified
2 marks for each explanation
[Total – 20 marks]
7.0. REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Books
12
Thomson Business Press
TABLE OF CONTENT
13
1.0. Introduction - - - - 14
2.0. Objectives - - - - 14
3.0. Types of Production - - - - 14
3.1. Job Production - - - - 14
3.2. Batch Production - - - - 14
3.3. Flow Production - - - - 14-15
3.4 Self Assessment Question - - - - 16
3.5 Self Assessment Answer - - - - 16
4.0 Conclusion - - - - 17
5.0 Summary - - - - 17
6.0 Tutor Marked Assignment - - - - 18
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 18
7.0 References - - - - 19
1.0 INTRODUCTION
This unit will take a look at the types of production vis-à-vis:
• Jobbing
• Batch Production
• Flow Production
14
2.0. OBJECTIVES
At the end of the unit, students should be able to:
(i) Mention the types of production
(ii) Differentiate between Jobbing and Batch Production
(iii) Explain Flow Production
It is a short-run production and, thus, does not have the benefits of larger scale. If
subjects the producer to “peaks and troughs” activities, resulting in insufficient use of
labour and equipment. This makes scientific assessment of cost difficult.
Batches of products are sometimes produced in lots that will minimize both carrying
and set-up costs of machines. Batch production has the tendency to lead to a higher
in-process inventory.
A series of batches of different products may with careful planning constitute what is
effectively continuous production.
Flow productions are usually typical by the assembly line or conveyor-belt system
15
3.4. SELF ASSESSMENT QUESTION
Differentiate between Jobbing and Batch Production
16
3.5. SELF ASSESSMENT ANSWER
• Both are non-continuous processes
• Jobbing is ‘short-run’ production while Batch is ‘long-run’
• Jobbing subjects produces to ‘peaks and troughs’ while Batch Production does
not.
• Jobbing is carried out by small firms, while Batch may be carried out by large
firms etc.
4.0. CONCLUSION
The types and methods used in the production of goods depend on the product and the
quantity produced.
17
5.0. SUMMARY
The method of production adopted by producers of goods depends on the product and
the quantity produced. There are three main types of production:
• Job Production
• Batch Production
• Flow Production
18
6.1. TUTOR MARKED ASSIGNMENT (ANSWER AND MARKING SCHEME)
Types of production are:
• Job Production
• Batch Production
• Flow Production
MARKING SCHEME
3 marks for each type of production identified
3 marks for each type correctly explained.
[Total – 20 marks]
7.0. REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Books.
19
2. Needle, David (1999): Business in Context, (London),
Thomson Business Press
20
TABLE OF CONTENT
1.0. Introduction - - - - 21
2.0. Objectives - - - - 21
3.0. Factory Location - - - - 21
3.1. Site Location - - - - 21
3.2. Types of Building - - - - 22
3.3. Positioning Departments - - - - 22
3.4 Self Assessment Question - - - - 23
3.5 Self Assessment Answer - - - - 23
4.0 Conclusion - - - - 24
5.0 Summary - - - - 24
6.0 Tutor Marked Assignment - - - - 25
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 25
7.0 References - - - - 26
1.0. INTRODUCTION
This unit will take a cursory look at factory location, with special reference to site,
building and positioning of departments.
2.0. OBJECTIVES
21
At the end of this unit students should be able to:
(i) Identify the factors that influence the choice of a factory site.
(ii) Mention different types of building.
(iii) State the principles relevant to the positioning of departments.
22
(b) Single-Storey Building
This idea for accommodating heavy machinery and for the movement of
materials. It is easier to alter them multi-storey building. They simple in
construction and cheaper to build.
(c) Multi-Storey Building
This will require artificial lighting, cheaper to heat as a result of less heat- loss
through the roof. To ensure easy traffic flow, gravity chute and lift must be
provided. Otherwise traffic is continued to separate the floors.
23
Examples of factory building are:
• Custom-built Factory
• Single-storey Building
• Multi-storey Building
4.0. CONCLUSION
Factory location is a key aspect of production that requires careful consideration in
order to ensure cost effectiveness.
24
5.0. SUMMARY
The main features of factory location are:
• Site location
• Types of Building
• Positioning of Department.
Factors and principles affecting these essential features must put into consideration
before deciding to locate the factory in any chosen area.
25
The factors that influence site location are:
• Effective Cost
• Availability of labour of the required type
• Labour Cost
• Transport Facilities
• Local By-laws
• Housing and Social Facilities
• Possibility of expansion
• Proximity of commercial service
MARKING SCHEME
1 ½ marks for each factor identified
1 ½ marks for each brief explanation
[Total – 20 marks]
7.0. REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Books.
26
2. Needle, David (1999): Business in Context, (London),
Thomson Business Press
TABLE OF CONTENT
27
1.0. Introduction - - - - 28
2.0. Objectives - - - - 28
3.0. Plant and Equipment - - - - 28
3.1. The Choice of Plant and Equipment - - - - 28-29
3.2. Maintenance - - - - 29
3.3. Material and Equipment Handling - - - - 29
3.3.1. Materials Handling - - - - 29-30
3.3.2. Equipment Handling - - - - 30
3.4 Self Assessment Question - - - - 31
3.5 Self Assessment Answer - - - - 31
4.0 Conclusion - - - - 32
5.0 Summary - - - - 32
6.0 Tutor Marked Assignment - - - - 33
6.1 Tutor Marked Assignment (Question and Marking Scheme)- 33
7.0 References - - - - 34
1.0. INTRODUCTION
This unit will take a look at plant and equipment, with specific reference to
maintenance, material handling and choice of equipment.
2.0. OBJECTIVES
28
At the end of this unit, students should be able to:
(i) Identify the factors to be considered in selecting plants and equipments.
(ii) Explain the concept of maintenance.
(iii) State the principles of material handling.
29
3.2. MAINTENANCE
Maintenance is a continuous process and, it is handled by specialist staff whose
responsibility includes:
• Regular inspection and servicing
• Repairs carried out on an emergency basis
• Supervising proper use by operatives
• Compiling records of breakdown performance etc
• Advising management about replacement.
There are different types of maintenance, these are:
• Predictive Maintenance
• Preventive Maintenance
• Corrective Maintenance.
Organizations may have maintenance policy specific to them but the general factors to
be considered are:
(a) The cost of production lost through breakdown
(b) The cost and effectiveness of inspection and maintenance
(c) Principle concerning obsolescence and replacement
(d) Buying policy as effected by maintenance work
30
Gravity chutes, hoists, lifts etc are used for vertical movement, whilst Trucks are used
for:
• Holding and discharging bulk or collection of items of dumper trucks.
• Picking up and transporting standard pallets on a platform made up into ‘unit
loads’ as pallet trucks.
31
Handling equipment are classified into:
(a) Bulk Materials
Moved with the aid of suction pipes and vacuum tube.
(b) Conveyors
Which mechanically motivated light packaging, shipped manually along
rollers belts, whilst heavy materials or goods are moved overhead by
conveyors which lift and lower.
(c) Trucks such as:
(i) Dumber Trucks
For holding and discharging bulk or collection of items.
(ii) Forklift
Trucks which pick up and carry a load and then stack it.
(iii) Pallet Truck
Which picks up and transport standard pallets on a platform, made up
into ‘unit loads’
(iv) Gravity chutes, hoists, lifts etc are used for vertical movement.
4.0. CONCLUSION
Plants and equipment are key aspect of the production section that requires careful
planning with adequate movement space for equipment and materials.
32
5.0. SUMMARY
Management must take some factors into consideration before selecting plant and
equipment. Maintenance policy must be well drawn out and allowance made for the
movement of equipment and material at the outset.
33
6.1. TUTOR MARKED ASSIGNMENT (ANSWER AND MARKING SCHEME)
The factors to be considered are:
(a) Special purpose machines
(b) General purpose machines
(c) Effective cost
(d) Size
(e) Maintenance and repairs
(f) Obsolescence
(g) Power
(h) Labour cost
(i) Output
MARKING SCHEME
1 point for each factor named
1 point for each brief explanation
[Total – 20 marks]
7.0. REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Books.
34
2. Needle, David (1999): Business in Context, (London),
Thomson Book Press
TABLE OF CONTENT
35
1.0. Introduction - - - - 36
2.0. Objectives - - - - 36
3.0. Production Planning and Control - - - - 36
3.1. Planning and Control - - - - 36
3.2. Progress Control - - - - 37
3.3. Inspection - - - - 37-38
3.3.1. Methods of Inspection - - - - 38
3.4 Self Assessment Question - - - - 39
3.5 Self Assessment Answer - - - - 39
4.0 Conclusion - - - - 40
5.0 Summary - - - - 40
6.0 Tutor Marked Assignment - - - - 41
6.1 Tutor Marked Assignment (Question and Marking Scheme)- 41
7.0 References - - - - 42
1.0. INTRODUCTION
This unit will take a cursory look at Production Planning and Control with special
emphasis on progress control and inspection.
36
2.0. OBJECTIVES
At the end of this unit, students should be able to:
(i) Identify the objectives of Planning and Control.
(ii) Identify the features of Progress Control.
(iii) State the purpose of Inspection.
Control on the other hand implies the setting of standards and objectives, the
coordinator of the various stages and the variation of plans as circumstances dictate.
The responsibility for these two functions rest with one department.
37
The need for progress control arises as a result of:
• Failure of materials to be delivered
• Machine or power breakdown
• Industrial action
• Delay at an earlier point on the production line
• Staff absenteeism
• Errors of design, planning or human activity
The main tasks of progress control are:
• To check progress continuously
• To determine the cause of any deviation
• To resolve the difficulty
• To adjust material delivery and to advice the sale.
Control can be assisted through:
• The use of flow chart which shows the planned sequence of operations
• The use of production schedule such as grant charts
• The use of automatic control to give a continuous feed back of information by
computer.
• The use of machine loading charts
• Inspection schedules
• Material list which specify the type and quantities of materials and components
for each product.
3.3. INSPECTION
Inspection is carried out to ensure that finished products reach a required standard and
to reduce the amount of ‘scrap’ and wasted labour.
The prime objects of inspection are:
• To establish standards
• To ensure conformity with standards
• To identify contributory factors to deviations
• To determine permitted deviations
• To ensure that periodic checks are continuous (i.e. schedule inspections)
• To provide management data about costs of deviation.
Inspection assumes the following forms:
• Inspection of raw materials
• Inspection of work in progress
• Process control
• Running test
• Quality control
• Statistical quality control
3.3.1. METHODS OF INSPECTION
Methods of inspection include:
(a) Centralized Inspection
This requires that work be sent to the inspection department before proceeding
to the next stage.
38
The main features are:
• It allows for easier supervising
• Inspection records are centralized
• The shop floor is kept clear for operatives.
(b) Floor Inspection
This required inspectors carry out their examination at the work point.
The main advantage of this method is that:
• Less time is lost in handling and transportation
• Fault-finding is immediate and may be remedied without delay.
39
The aids to control available to management are:
• Flow charts
• Production schedules, e.g. Gantt charts
• Automatic control
• Machine loading charts
• Inspection schedules
• Material lists etc.
4.0. CONCLUSION
Failure to plan is planning to fail. Management must take advantage of the object of
planning and control for increased productivity.
40
5.0. SUMMARY
The prime objects of planning and control are:
• To co-educate labour and machines in the most effective and economic way
• To establish targets, check them against performance and to take necessary actions
• To achieve smooth continuous production.
These aims are achieved through a well planned programme of action.
41
The prime objectives of inspection are:
• To establish standards
• To ensure conformity with standards
• To identify contributory facts to deviation
• Schedule inspections
• Provide management data about costs of deviations, the on delivery etc.
MARKING SCHEME
4 marks for each objective correctly stated
[Total – 20 marks]
7.0. REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Books
42
2. Needle, David (1999): Business in Context, (London),
Thomson Book Press
1.0. Introduction - - - - 44
43
2.0. Objectives - - - - 44
3.0. Work Measurement - - - - 44
3.1 The Concept and Objectives of Work Measurement - - - 44
3.2 Work Measurement Procedure and Measurement Techniques- - 44
3.2.1. Work Measurement Techniques - - - - 44-45
3.3 Attitude-to-work study - - - - 45
3.4 Self Assessment Question - - - - 46
3.5 Self Assessment Answer - - - - 46
4.0 Conclusion - - - - 47
5.0 Summary - - - - 47
6.0 Tutor Marked Assignment - - - - 48
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 48
7.0 References - - - - 49
1.0 INTRODUCTION
This unit will expose us to the objectives, procedure and technique of work study.
2.0 OBJECTIVES
44
At the end of this unit, students should be able to:
(i) State the objectives of work measurement.
(ii) Identify the techniques of work measurement.
(iii) Enumerate the problems associated with work study.
45
(iv) Activity Sampling
This involves making observations and recording what is happening on an
agreed number of visits in a period at random. Idle time of a machine is
calculated by noting at the random sampling, if the machine is working.
46
The problems suspicious are:
• Fear of redundancy
• Reliability of the standard
• Effect on incentives
• Resentment of being watched.
4.0 CONCLUSION
You have now successfully completed the study on one of the techniques of work
study which will help you to improve on your task performance efficiency.
47
5.0 SUMMARY
Work measurement is one of the techniques of work study. The procedure is similar
to that of method study but with emphasis on quantifications. It provides a basis for
designing an effective incentive scheme and to check performance with standards.
48
The techniques of work measurement are:
• Direct time study
• Predetermined motion time system
• Analytical estimating
• Activity Sampling
MARKING SCHEME
3 marks for each technique named
2 marks for each explanation
[Total – 20 marks]
7.0 REFERENCES
49
UNIT 7: METHOD STUDY
TABLE OF CONTENT
1.0. Introduction - - - - 51
50
2.0. Objectives - - - - 51
3.0. Method Study - - - - 51
3.1 Concept and meaning of Method Study - - - - 51
3.2 Objectives of Method Study - - - - 51
3.3 Method Study Procedure - - - - 51-52
3.4 Self Assessment Question - - - - 53
3.5 Self Assessment Answer - - - - 53
4.0 Conclusion - - - - 54
5.0 Summary - - - - 54
6.0 Tutor Marked Assignment - - - - 55
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 55
7.0 References - - - - 56
1.0 INTRODUCTION
This unit will take a cursory look at method study vis-à-vis the objectives and
procedures.
2.0 OBJECTIVES
51
At the end of this unit, students should be able to:
(i) State the objectives of method study.
(ii) Enumerate the procedures of method study.
(iii) State the meaning of method study.
(c) Analyze the records and quantity where appropriate with a view at making some
improvement through:
• eliminating an operation or part of it.
• combining one or more operations
• devising different physical movement
• altering machine tools
52
• altering the sequence of operations.
53
The devices used are:
• Process charts and flow diagrams
• Multiple activity charts
• Motion charts
• Simo-charts
• Layout models and templates
• String diagrams
• Films and still cameras.
4.0 CONCLUSION
With the knowledge you have acquired in this unit, you are now in a position to carry
out a Method Study of any organization.
54
5.0 SUMMARY
Method Study is the scientific analysis of operations and the way in which all
operations are co-ordinated with a view at devising better approaches. It is one of the
methods of work study.
55
• Analyze the record and quantity where appropriate
• Design a new method
• Record the new method and produce a mathematical comparison with the old.
• Install the new method and provide instruction for its use.
• Record the new method in operation and adjust where appropriate.
MARKING SCHEME
2 marks for each procedure stated
1 mark for each correct explanation
[Total – 20 marks]
7.0 REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Handbooks
56
UNIT 8: PRODUCTION ENGINEERING
TABLE OF CONTENT
57
1.0. Introduction - - - - 58
2.0. Objectives - - - - 58
3.0. Production Engineering - - - - 58
3.1 The Concept of Simplification and Standardization - - - 58
3.1.1 Advantages of Simplification and Standardization - - - 58
3.1.2 Disadvantages of Simplification and Standardization - - - 58
3.2 Specialization - - - - 59
3.3 Diversification - - - - 59
3.4 Self Assessment Question - - - - 60
3.5 Self Assessment Answer - - - - 60
4.0 Conclusion - - - - 61
5.0 Summary - - - - 61
6.0 Tutor Marked Assignment - - - - 62
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 62
7.0 References - - - - 63
1.0 INTRODUCTION
This unit will introduce you to the concept of standardization and simplification as
well as specialization and diversification.
2.0 OBJECTIVES
At the end of this unit, students should be able to:
58
(i) State the merits and demerits of standardization and simplification.
(ii) Explain the concept of diversification.
(iii) Explain specialization.
Simplification is the process whereby the range of components and/or final products
are reduced. It entails producing more of any one type to gain the advantage of large-
scale production.
3.2 SPECIALIZATION
This is the case, when an organization decides to concentrate on a narrow range of
products. It enables the manufacturer to remain in the areas where he is most
59
experienced and have a well-established production process, labour and technical skill
required and a sound knowledge of the market.
The demerits of product specialization are:
• over-dependence on one market
• may be overtaken by a new technology
• inflexibility.
On the other hand, specialization of labour will entail reducing the range of skill
required of each worker so that efficiency is improved by concentration of efforts.
3.3 DIVERSIFICATION
This entails venturing into new areas of production. It is the direct opposite of
specialization. Organizations embark on diversification for the following reasons:
• To reduce risk of over dependent on one product.
• To utilize spare capacity
• To offer a wider range within the same market
• To put by-products to profitable use
• As a result of integration.
60
• It utilizes spare capacity
• It offers wider range within the same market
• It puts by-products to profitable use
• It is a result of integration.
4.0 CONCLUSION
Now that you gone through this unit, you are better placed to appreciate the merits
and demerits of simplification and standardization, specialization and diversification.
5.0 SUMMARY
61
Production engineering embraces the totality of the production processes in an
organization vis-à-vis,:
• Implementation of production policy
• Production span
• Establishment of standards
• Design of tools and equipments
• Measurement of performance
• Working within cost limits.
62
The merit of simplification and standardization are:
• Reduction of unit costs
• Easier inspection
• Reduced cost of design stage
• Reduced variety of skill required
• Lower tooling cost
• More efficient customer service for spares and repairs
• Simpler organization
• Less complex purchasing
MARKING SCHEME
3 marks for each merit correctly stated
[Total – 20 marks]
7.0 REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Handbooks
63
UNIT 9: THE PRODUCTION FUNCTION
TABLE OF CONTENT
1.0. Introduction - - - - 65
2.0. Objectives - - - - 65
64
3.0. The Production Function - - - - 65
3.1 The Universality of Production - - - - 65
3.2 Difference Between Manufacturing and Non-manufacturing Industries- 65-66
3.3 Identifying the Production Function - - - - 66
3.4 Self Assessment Question - - - - 67
3.5 Self Assessment Answer - - - - 67
4.0 Conclusion - - - - 68
5.0 Summary - - - - 68
6.0 Tutor Marked Assignment - - - - 69
6.1 Tutor Marked Assignment (Question and Marking Scheme) - - 69
7.0 References - - - - 70
1.0 INTRODUCTION
This unit will consider the production function as a universal concept.
2.0 OBJECTIVES
At the end of this unit, students should be able to:
(i) Identify the production function.
(ii) Differentiate between the manufacturing and non-manufacturing industries.
65
(iii) Explain the universality of production.
66
The primary function of production is to convert inputs into different kinds of outputs.
This view of production function is commonly referred to as the system view of
production.
It entails:
(a) The Input such as:
• Raw materials
• People
• Energy
• Machines
• Fixed assets
• Method of working
• Information.
67
The principal function of production is to transform input into different kinds of
output. This is referred to as the system view of production. It embraces the input,
process and output.
4.0 CONCLUSION
A form of production takes place in every organization, whether manufacturing or
non-manufacturing hence the concept “universality of production”
68
5.0 SUMMARY
The function of production is universal. It takes place in every organization whether
profit or non-profit, manufacturing or non-manufacturing. The key function of
production is to convert input into output.
69
Key points
• The production function exists in every organization
• It transforms input such information, people, material and feviance into the
desired output.
• Is a key aspect of management strategy
• Is pivotal to organizations’ success
• It represents the bulk of a firm’s assets, expenditure and people.
MARKING SCHEME
4 marks for every concept named and explained
[Total – 20 marks]
7.0 REFERENCES
1. Needle, David (1999): Business in Context, (London),
Thomson Business Press
70
2. Hill, .S. (1991): Production and Operation Management: Text and Cases, (London),
Prentice Hall
TABLE OF CONTENT
1.0. Introduction - - - - 72
71
2.0. Objectives - - - - 72
3.0. System Design - - - - 72
3.1 Forecasting Demand and Capacity Planning - - - - 72
3.2 Equipment and Work Design - - - - 72-73
3.3 Location Decision - - - - 73
3.4 Self Assessment Question - - - - 74
3.5 Self Assessment Answer - - - - 74
4.0 Conclusion - - - - 75
5.0 Summary - - - - 75
6.0 Tutor Marked Assignment - - - - 76
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 76
7.0 References - - - - 77
1.0 INTRODUCTION
This unit will take a look at system design vis-à-vis capacity planning Equipment
design, work design and location decision.
2.0 OBJECTIVES
At the end of this unit, students should be able to:
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(i) Identify the strategies used by companies to reduce difficulties imposed by
capacity planning.
(ii) State the types of decision relevant in work design.
(iii) State the factors that determine the choice of location.
To carry out an effective forecast, accurate information concerning the market and
accurate prediction of demand is required. Getting this information is particularly
difficult in a highly volatile market of changing demand and high levels of
competition.
In a situation where forecasting made with some degree of accuracy capacity planning
may still not be straight forward. It is sensitive to product and process innovation and
is affected by decision on the type of technology used, organization size and structure
and the extent to which subcontracting as well as other policies in delivery service
industries are faced with many challenges. This necessitates the need for capacity
planning. The strategy adopted may include:
• Operating a fixed schedule
• Insisting that passengers or customers buy tickets before hand
• Creating extra capacity particularly during times of high demand
• Operating a delayed delivery system to control demand and plan capacity
• Introducing overtime to cater for overbooking
• Using demand and capacity as a marketing strategy where a product develops a
rarity value and cult status
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which are collectively referred to as Work Study. While work measures apply
techniques designed to establish the time for a qualified worker to carry out a task at a
defined level of performance. This technique is commonly referred to as Time Study.
Method Study on the other hand is the systematic and critical examination of the ways
of doing things in order to make improvement (British Standard 3138).
74
3.5 SELF ASSESSMENT ANSWER
(1) The factors are:
• product design
• capacity planning
• skill of the labour force
• accounting procedure.
4.0 CONCLUSION
75
System design embraces product design, forecasting demand, capacity planning,
equipment design and work design which are key factors in management production
strategy.
5.0 SUMMARY
The key factors in system design are:
• Forecasting demand
• Capacity planning
• Equipment design
• Work design
• Location decision.
76
Enumerate the strategies used by service industries to reduce the difficulties imposed
by capacity planning.
MARKING SCHEME
3 points for each strategy enumerated and explained
[Total – 20 marks]
7.0 REFERENCES
77
1. Wild, R. (1985): Essentials of Production and Operation Management, (London),
Holt Rinehart and Winston
78
TABLE OF CONTENT
1.0. Introduction - - - - 79
2.0. Objectives - - - - 79
3.0. System Operations - - - - 79
3.1 Operations Planning - - - - 79
3.2 Operations Control - - - - 79-80
3.3 Scheduling - - - - 80
3.4 Self Assessment Question - - - - 81
3.5 Self Assessment Answer - - - - 81
4.0 Conclusion - - - - 82
5.0 Summary - - - - 82
6.0 Tutor Marked Assignment - - - - 83
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 83
7.0 References - - - - 84
1.0 INTRODUCTION
79
The unit will consider production system operation vis-à-vis operations planning
operations control and scheduling.
2.0 OBJECTIVES
At the end of the unit, students should be able to:
(i) Explain operations planning.
(ii) State the aims of scheduling.
(iii) Identify various types of operations control.
(2) Quality Control: This ensures that the quality of the furnished product or
service meets the standards set in the design stage and meet with approval of
customer.
(4) Labour Cost: The prime focus here are, what should be the extent and style
of supervision and the type of incentive to be used to generate the right
response and co-operation from the labour force?
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(5) Cost Control: This is essentially an accounting function. It entails the
collection and analysis of data on material, operating equipment and labour
cost and comparisons made with previously determined standard costing.
3.3 SCHEDULING
The primary aim of scheduling is to balance the costs of production against demands
for goods and services to ensure that demand is met in the most efficient way
possible.
81
Mention and explain the techniques used to ensure optimal solution to the problem of
scheduling.
4.0 CONCLUSION
82
System operation is a key aspect of the production system. It consists of operation
planning, operation control and scheduling.
5.0 SUMMARY
The key aspects system operations are:
(i) Operation, planning which is primarily concerned with ensuring that sufficient
goods or services are produced to meet demand.
(ii) Operation control, which consists of:
• Quantity control
• Quality control
• Technology control
• Labour cost
• Cost control.
(iii) Scheduling, which is aimed at balancing the cost of production against
demand for goods and services.
83
State and explain the various types of operations control.
MARKING SCHEME
2 marks for each type named
2 marks for each explanation
[Total – 20 marks]
7.0 REFERENCES
84
1. Needle, David (1999): Business in Context, (London),
Thomson Business Press
85
TABLE OF CONTENT
1.0. Introduction - - - - 86
2.0. Objectives - - - - 86
3.0 The Production Process as a System - - - - 86
3.1 Inputs of Production - - - - 86
3.2 Process of Production - - - - 86-87
3.3 Output of production - - - - 87
3.4 Self Assessment Question - - - - 88
3.5 Self Assessment Answer - - - - 88
4.0 Conclusion - - - - 89
5.0 Summary - - - - 89
6.0 Tutor Marked Assignment - - - - 90
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 90
7.0 References - - - - 91
1.0 INTRODUCTION
86
The unit will consider the process of transforming inputs into outputs.
2.0 OBJECTIVES
At the end of this unit, students should be able to:
(i) Identify the input of production.
(ii) Explain the process of converting input into output.
(iii) Identify the output of production.
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• Process-focused system.
The Product-focused System groups together all of the machines, tools and workers
needed to perform all of the tasks required to finish a product.
It is designed to produce a few standardized products in high quantity at low cost.
The Process-focused Systems are designed to produce many unique product designs
in relatively low volumes. Here, the production department is designed to perform
only one kind of task to a group of products being produced on batch production
system.
88
3.4 SELF ASSESSMENT QUESTION
What are the undesirable output of production?
89
4.0 CONCLUSION
The production system is a transformation process. It converts input into desirable
output.
5.0 SUMMARY
The production system consists of input, process and output. Key input are raw
materials, people, energy, machines, fixed assets, method of working and information
while process refers to the conversion of input in combination to produce desirable
output. Output are either desirable or undesirable.
90
6.0 TUTOR MARKED ASSIGNMENT
What are the input of production?
MARKING SCHEME
2 marks for each correctly named and explained.
[Total – 20 marks]
91
7.0 REFERENCES
1. Needle, David (1999): Business in Context, (London),
Thomson Business Press
92
UNIT 13: PRODUCTION AND PRODUCTIVITY
TABLE OF CONTENT
1.0. Introduction - - - - 93
2.0. Objectives - - - - 93
3.0. Production and Productivity - - - - 93
3.1 Concepts and Scope - - - - 93
3.2 Capacity Measurement - - - - 93
3.3 Cycle Time and Labour Requirement - - - - 94
3.4 Self Assessment Question - - - - 95
3.5 Self Assessment Answer - - - - 95
4.0 Conclusion - - - - 96
5.0 Summary - - - - 96
6.0 Tutor Marked Assignment - - - - 97
6.1 Tutor Marked Assignment (Question and Marking Scheme)- - 97
7.0 References - - - - 98
93
1.0. INTRODUCTION
The unit will consider the concept of production and productivity with specific
reference to capacity measurement and performance indices.
2.0. OBJECTIVES
At the end of this unit, students should be able to:
(i) Explain the concept of production and productivity.
(ii) Explain capacity measurement.
(iii) Discuss cycle time and labour requirement.
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3.3 CYCLE TIME AND LABOUR REQUIREMENT
Processing systems are either automatic, semi-automatic or batch. In automatic
systems, operations are required to load and set the machine running. They are also
required to unload, clean and carry out minor adjustments to enhance efficient
operation. The number of operatives required depends on the number of machines an
operator can tend to at a time. Since all the machines cannot develop faults, at the
same time, the operator is free to attend to the one demanding his attention while
other machines are running. A perfect balance is, however, difficult to attain in the
assignment process. Lockyer (1983) assumes that work to carry out in different
machines should be identical in terms of cycle time, that is the actual processing time,
unloading and allowance for personnel and other needs. In addition to machine
capability, there is the need to consider the workers’ performance in tending to
machines in capacity assessment Using Time Study, the time to perform a particular
task is derived and converted to basic time, using the rating factors. Relaxation and
other contingency allowances are added to get what is known as Standard Time.
If on the average the performance is higher than the standard, performance is assumed
to be 100%, and then there will be an increase in capacity availability.
95
3.4 SELF ASSESSMENT QUESTION
What is the relationship between Cycle Time and Labour Requirement?
96
4.0 CONCLUSION
Machine productivity is enhanced by labour productivity.
5.0 SUMMARY
Productivity study is primarily aimed at the best way to improve production at a
reduced cost. Capacity measurement should take cognizance of workers’ performance
through the use of time study. Our knowledge of standard and actual performance will
help us not only to capacity availability but also labour requirement.
97
6.0 TUTOR MARKED ASSIGNMENT
What is production?
MARKING SCHEME
2 points for each element of productivity correctly named and briefly explained
[Total – 20 marks]
98
7.0 REFERENCES
99
UNIT 14: FACTORY AND WORK PLACE LAYOUT
TABLE OF CONTENT
100
1.0 INTRODUCTION
The unit will address the concept and scope of factory and work place layout.
2.0 OBJECTIVES
At the end of this unit, students should be able to:
(i) Explain the meaning of Factory Layout.
(ii) State the advantages of Process Layout.
(iii) State the merits of Product Layout.
In an ideal factory, the new material may come in at one end, pass through all the
processes of manufacture and emerge as the finished product for dispatch at the other
end.
In like manner, raw materials may come in at one door, pass right round the factory,
undergoing various operations and go out at the same time.
The principles of straight line flow are still valid, even where there several parts going
into the finished products, although it may necessary to introduce converging lines, of
flow with components or parts stored at various points on the production line.
The various recording techniques used in the study of factory layout and work flow
are:
• Process charts
• Flow diagrams
• String diagrams
• Multiple activity charts.
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3.2. PROCESS LAYOUT
In process layout, similar equipment, that is machine that perform similar functions,
are grouped together. It is also referred to as functional layout. Each department
consists of groups of similar machine or people doing similar jobs such as carding,
drawing, spinning etc. All these activities are collectively referred to as spinning
process or operations in textile industries.
102
3.4. SELF ASSESSMENT QUESTION
State the advantages of Product Layout.
103
4.0. CONCLUSION
For easy mobility, a good factory layout is required. A good factory layout will
facilitate free-flow movement of personnel and materials.
5.0. SUMMARY
Factory Layout is the arrangement of machines, offices, equipment, light electrical
outlets, store room and all other facilities in the plant or office.
The prime object of Factory Layout is to permit the efficient flow of people and
materials.
104
6.0. TUTOR MARKED ASSIGNMENT
What are Factory and Work Place Layout?
MARKING SCHEME
2 marks for every accurate identification and brief explanation of Factory and Work-
place Layout
[Total – 20 marks]
105
7.0. REFERENCES
1. Pitfield, R. Ronald (1984): Business Organization, (London),
M & E Handbooks
106
UNIT 15: AGGREGATE PRODUCTION PLANNING
TABLE OF CONTENT
107
1.0. INTRODUCTION
This unit will consider one of the methodologies of production planning and control
2.0. OBJECTIVES
At the end of this unit, students should be able to:
(i) Explain the concept of Aggregate Production Planning.
(ii) Identify the factors that will enable managements to decide whether to produce-to-
order or produce-to-stock.
(iii) Identify the problems inherent in Aggregate Plans for services.
The plan will spell out the amount of straight time and over-time labour, amount of
subcontracting and other sources of capacity to the used.
It derives its information from product demand forecast, customer order, inventory
level and factory capacity level.
108
• Transform the aggregate demand for each time period into workers, materials,
machines and other elements of production capacity required to satisfy aggregate
demand.
• Develop alternative resources schemes of supplying the necessary production
capacity to support the cumulative aggregate demand.
• Select the capacity plan for among the alternative.
PRODUCE-TO-STOCK PRODUCE-TO-ORDER
1. Finished products inventory buffers the The firm begins production only when
difference between the level of production orders are received; the purpose of
capacity and the variable quantity demand. buffering growth cannot be achieved.
2. Finished product storage serves the same There is backlog because demand
purpose as backlog in produce-to-order. exceeds production capacity.
Where a service system supplies, customized services to customers, difficulty will rise
in course of specifying the nature and extent of service, and hence aggregate planning
becomes difficult. Examples of such systems are hospitals, computer service centres,
automobile body repair shops etc.
109
Key problems associated with aggregate plan for service are:
110
3.4. SELF ASSESSMENT QUESTION
Identify the problems associated with aggregate plan for service.
111
4.0. CONCLUSION
Now that you have gone through this unit, you can clearly show that aggregate plan is
aimed at providing enough production capacity to satisfy market demand at the lowest
possible cost.
5.0. SUMMARY
Aggregate plan involves devising a plan for production capacity for a period not less
than six months. The primary aim is to ensure enough production capacity to meet
market demand and lowest cost possible.
112
6.0. TUTOR MARKED ASSIGNMENT
Itemize the necessary steps in Aggregate Planning
MARKING SCHEME
4 marks for each step correctly named and explained
[Total – 20 marks]
113
7.0. REFERENCES
1. Needle, David (1999):Business in Context, (London),
Thompson Business Press
114